Carrier and method

ABSTRACT

The carrier has beverage cup-holding receptacles on opposite sides of a vertical support panel, and a third much larger receptacle formed from the same blank. The carrier is stored flat and is unfolded for use at a usage location such as a motion picture theater concession stand, where it can be used to carry beverage cups in the smaller receptacles and popcorn in the large receptacle. An auxiliary tray can be mounted on an upright handle structure through a slot in the bottom, and can be used to carry other food item such as candy, hot dogs, etc. The carrier can be used to carry out fast foods such as fried chicken, french fries and beverages. Solid, bulky foods such as popcorn and fried chicken can be carried in the larger receptacle directly, without the use of a bucket or other separate container.

This patent application is a Continuation-in-Part of U.S. Ser. No. 11/012,789, filed Dec. 15, 2004.

This invention relates to carriers and methods of using and manufacturing same, and particularly to carriers and methods for use in distributing food and beverages.

Even more particularly, the invention relates to carriers and methods for carrying a wide variety of objects of widely varying sizes in a single carrier.

In the prior above-identified patent applications, the carriers described there are adapted for hand-carrying beverages, solid food, and a variety of objects such as motor oil cans and similar objects. Although those carriers are highly desirable, the ability to carry containers of widely varying sizes is somewhat limited.

In particular, in many so-called “fast food” stores, movie theaters, etc., food and beverages are sold which are of relatively moderate size, along with much larger containers such as the so-called “buckets” containing popcorn, or fried chicken, or fried fish or shrimp, etc.

Accordingly, it is an object of the present invention to provide a carrier and distribution method in which both relatively small items, such as beverage containers and relatively large containers, such as “buckets” or comparable quantities of loose items of solid food can be carried in a single carrier.

It is another object to provide such a carrier in which smaller solid food items, such as hamburgers, hotdogs, sandwiches, candy bars and packages, etc., also can be carried, preferably separately from the other items.

It also is an object of the invention to provide such a carrier which is sturdy, relatively inexpensive to manufacture, easy to set up by food distribution personnel and/or customers, and relatively easy to carry, preferably with one hand.

In accordance with the present invention, the foregoing objects are satisfied by the provision of a carrier and method in which a vertical central support structure is provided, with a pair of foldable receptacles extending from opposite sides of the central support structure, when the carrier is unfolded, and a lateral extension which provides a third receptacle for carrying either a container of much larger diameter than those which can be carried in the two first mentioned containers, so as to hold “buckets” of popcorn, fried chicken, etc., or as a complete container for such foods, without the bucket.

In providing such a carrier, it is preferred that the basic carrier construction described in my prior patent applications be utilized, with modifications, to provide the carrier structure.

An open tray with a slot in the bottom, or a closed box with slots in both the top cover and the bottom can be used by slipping the tray or the box over the upright central support/handle structure so as to carry additional solid items such as hotdogs, hamburgers, boxes, bags or bars of candy or fruit, etc.

In one specific embodiment of the invention, retainer panels with one or two beverage-receiving holes are provided to fit over the tops of the smaller carrier receptacles so as to stabilize and hold the beverage containers and prevent them from slipping or tipping from side-to-side in the receptacles.

The foregoing and other objects and advantages of the invention will be apparent from or explained in the following description and drawings.

IN THE DRAWINGS

FIG. 1 is a perspective view of a carrier constructed in accordance with the present invention;

FIG. 2 is a cross-sectional, broken away view taken along lines 2-2 of FIG. 1;

FIG. 3 is a bottom plan view of the carrier shown in FIG. 1, with the carrier partially unfolded;

FIG. 4 is a partially schematic side elevation view of the carrier of FIG. 1 containing a bucket, beverage containers and a tray, as used in accordance with one embodiment of the present invention;

FIG. 5 is a top plan view of a ray used in the embodiment shown in FIG. 4;

FIG. 6 shows a fiberboard blank used to make the carrier of FIGS. 1-4;

FIG. 7 is a perspective view of another embodiment of the carrier of the invention;

FIG. 8 is a perspective, partially broken away, and partially schematic cross-sectional view taken along line 8-8 of FIG. 7;

FIG. 9 is a top plan view of a blank used to make the carrier of FIGS. 7 and 8;

FIG. 10 is a perspective view of another embodiment of the carrier of the invention;

FIG. 11 is a top plan view of a blank used to make the carrier of FIG. 10;

FIG. 12 is a top plan view of a blank used to make an auxiliary tray for use with the carrier of FIGS. 10 and 11; and

FIG. 13 is a side elevation view of the auxiliary tray formed from the blank of FIG. 12.

GENERAL DESCRIPTION

FIG. 1 shows a first embodiment 10 of the carrier of the present invention.

The carrier 10 includes a vertical support structure 12. Two foldable receptacle structures 35 and 37 are secured to and extend from the vertical support structure 12 when the carrier is unfolded.

One receptacle structure 35 includes side-walls 26, 28 and 30, and the second receptacle structure 37 includes vertical side-walls 32, 34 and 36. Flaps 42 and 44 extend from the vertical support structure 12 and are glued to the inside surfaces of panels 30 and 32, respectively. Foldable bottom structures 60 and 62 extend from the bottom walls of the receptacle structures.

Dividers 46 and 48 extend from the vertical support structure 12 to the opposite side-walls 28 and 34 and are glued thereto by means of tabs 48 and 52, respectively. The dividers 46 and 50 are positioned relatively close to the ends 30 and 32 so that the receptacles 35 and 37 are relatively small. The walls 28, 34 and bottom structure 60, 62 extend laterally from the dividers by a relatively greater distance to form a third much larger compartment or receptacle 39 to the side of each receptacle.

Central Support Structure

The central support structure 12 includes a pair of relatively tall vertical panels 18 and 20 which are glued together back-to-back. A four-ply handle portion is formed by panels 14 and 16, which are glued, respectively, to the upper portions of panels 18 and 20. A handle hole 22 is provided near the upper edge of the structure 12, with a folding finger guard structure 24.

It should be understood, of course, that equivalent structures can be made utilizing only a two-ply or one-ply vertical support structure, depending upon the weight of the fiberboard used, expected loads to be carried, etc.

The large receptacle 39 formed by the lateral extension of the side-walls 34 and 28 and the bottom walls 60 and 62 is strengthened by extending the panels 18 and 16 at their lower edges to form extensions 58 and 59, which are glued together to form a stiff, short vertical spine at the bottom of the large receptacle 39. Flaps 38 and 40, extending from the leftmost edges of the panels 26 and 36, respectively, are glued together, folded over and glued to the panel 36, as shown.

Bottom Structures

The bottom structures 60 and 62 are illustrated in FIGS. 1, 2 and 3, as well as in FIG. 6.

Each bottom structure 60 or 62 includes a broad top flange or panel 64 hinged at one edge to the panel 18 or 20 and the spine formed by panel portions 58 and 59.

As in prior embodiments of the carriers shown in the above-identified pending patent applications, the panels 64 and 65 advantageously extend completely across the bottom of the receptacles they form. Each panel. has three short projections 66, 68 and 70 or 72, 74 and 76, which fit through slots 78, 80 and 82 or 84, 86 and 88 when the panels 64 and 65 are completely unfolded and pressed downwardly by use of hand pressure, or by the pressure of beverage containers resting on the panels.

The bottom structures 60 and 62 are very much the same as the bottom structure shown in my above-identified pending patent applications in that they open automatically when the folded ends of the folded carrier are pushed towards one another (in the directions indicated by the arrows 61 and 63 in FIG. 3) so that the structure forms a strong platform to support the top panel 64 or 65 and objects in the receptacles.

As it is shown in FIGS. 2 and 3, at the rear corner of the receptacle 35 is a flange or flap 90 with a tab 94 which is secured to a long flange 106 and which has a diagonal fold line 95. Similarly, at the front of the carrier, a flap 98 extends from the front wall 30 with a tab 102 which is glued to the undersurface of the panel 64. The flap 98 folds along a diagonal line 99.

Similarly, the bottom structure 62 includes a flap or flange 92 hinged to the bottom edge of panel 36. The flange 92 has a tab 96 which is glued to a flange 108. The flange 92 has a diagonal fold line at 97.

Finally, at the front of structure 62, a flange 100 with a tab 104 is hinged to the wall 32. The tab 104 is glued to the panel 65 and has a diagonal fold line 101.

Referring again to FIG. 1, as well as to FIG. 6, it can be seen that the panels 64 and 65 are basically rectangular in shape. The rectangular shape has a beneficial aspect in that, when the flanges 64 and 65 are pulled downwardly by the corner tabs, the flanges tend to fill the space between the front and back walls of the receptacles 35 and 37 so that, once the carrier is unfolded by pressing on the folded ends of the carrier, the carrier will stay open when resting upon a counter so as to facilitate filling it with items to be carried in the carrier.

When the carrier is folded flat, the rear corners of the panels 64 and 65 are folded downwardly along the fold lines 67 and 69, respectively, due to engagement with the panels 26 and 36. As the carrier is opened and the panels 64 and 65 are pressed downwardly, the corners of the panels press against the panels 26 and 36 and, when the tabs along the edges of the panels 64 and 65 fit into the mating slots, the carrier is held fully open. Advantageously, the seating of the tabs in the slots can be performed simply by placing beverages in the beverage receptacles so that the weight of the beverages will press downwardly on the panels and properly seat them.

It should be noted that the bottom edges 54 and 56 of the dividers 46 and 50 are cut at an upward angle as shown, in order to prevent interference between the panels 64 and 65 and the dividers as the carrier is being unfolded.

Food Distribution

FIG. 4 illustrates the use of the carrier 10 in a typical food distribution process.

Assume, as an example, that the carrier 10 is being used in a movie theater selling beverages in cups 114, “buckets” 110 filled with popcorn 112, and candy bars, in boxes or bags.

First, the carrier blank is opened by pressing on the ends of the blank in the directions 61, 63 (FIG. 3), the beverages 114 are put in the receptacles 35 and 37, a bucket 110 of popcorn 112 is placed in the larger container 39 as shown in FIG. 4, with the bottom of the bucket resting on the vertical spine 58, 59. The popcorn is very light-weight and is mostly balanced by the weight of the beverages 114 so that it is relatively easy to carry the popcorn and the beverages with one hand by using the handle 22.

If the customer purchases bags, boxes or bars of candy, or other solid foods such as hot dogs, these can be placed in a tray 116 which slips onto the upper portion of the vertical support structure 12. Thus, the customer can carry, in one hand, beverages, a large container of popcorn, and candy, etc., in the tray. Most of the weight is centered directly underneath the handle.

If the bucket 110 holds a relatively heavy substance such as fried chicken or shrimp at 112 instead of the lighter-weight popcorn, it might be desirable to help support the left portion of the carrier with the other hand.

FIG. 5 is a top plan view of the tray 116, which is shown in greater detail in several of the above-identified co-pending patent applications. The tray 116 has a bottom wall 120 with an elongated slot 122 through which the vertical support structure 12 fits. It has four side-walls 124, 126, 128 and 130 which are angled upwardly as shown, with the sides being glued together at the corners.

If preferred, a closed food box can be used instead of the open tray 116, as is described in my co-pending application Ser. No. 10/939,264 filed Sep. 10, 2004, and as further described hereinbelow The closed container can contain donuts, bagels, pizza, or other comestibles, which can be heated in the box prior to the box being attached to the carrier.

Smaller beverage cups might not fill the receptacles 35 and 37. For that and other reasons, it may be desired to provide means for holding the beverage cups stable against tipping or sliding sideways.

This can be performed, in accordance with another feature of the invention, by adding flaps 154 and 156, shown in dashed outline in FIG. 6, which fold over the top of the beverage compartments and have holes 158 and 160, respectively, to embrace a semi-cylindrical beverage cup and hold it steady.

The use of this feature is illustrated schematically in FIG. 1 where the beverage retainer hole 160 is shown in dashed outline. Preferably, the dimensions of the panels 154 and 156 are such as to cause them to rest on the upper edges of the side-walls of the receptacles.

Carrier-Forming Blank

FIG. 6 shows a blank for the carrier 10. The blank is formed advantageously from a single sheet of fiberboard material. Fold-lines are marked with the letter “F”, and areas to which glue is applied are marked with the letter “G”.

The carrier can be manufactured with a single die cutting step from a single sheet of material, with folding and gluing steps following thereafter.

The carrier can be manufactured in relatively high volume at a relatively modest cost.

FURTHER EMBODIMENT

FIGS. 7-9 show the preferred carrier 131 of the invention. This carrier 131 is substantially the same as the carrier shown in FIGS. 1-6, with certain variations. Accordingly, the same reference numerals have been used for the parts of the carrier 131 corresponding to parts of the carrier 10 shown in FIGS. 1-6.

One of the differences between the carrier 131 shown in FIGS. 7-9 and that shown in FIGS. 1-6 is that the rear portions of the vertical side-walls 26, 28, 34 and 36 are considerably taller than the corresponding walls of the first-disclosed carrier. The taller walls are given a curved cut at 148 or 150 to reduce their height at the front end of the carrier to provide ready access to the receptacles 35 and 37.

Another change in the carrier 131 is the provision of two foldable sealing panels 136 and 138 for sealing the large receptacle 39 from the smaller receptacles 35 and 37 to enable popcorn, fried chicken or other particulate items to be carried in the large container 39 without a bucket and without leaking those items into the smaller receptacles.

Each panel 136 and 138 is hinged along a fold line 134 or 132 so that it can be folded downwardly to the position shown in the directions indicated by arrows 144 and 146. As it is shown in FIG. 8, each panel 136 and 138 forms a vertical wall closing the space below the lower edge 54 or 56 of the divider 46 or 50 to seal the large receptacle from the smaller ones.

optionally, tabs 140 and 142 (FIG. 8) can be provided at the edges of the panels 136 and 138 to mate with properly located slots in the bottom structure of the carrier to lock the security panels 136 and 138 into place. Alternatively, the locking function can be performed simply by insuring a frictional engagement between the lower edge of each panel 136 and 138 and the corresponding bottom structure of the receptacle in which it is located.

When the carrier 131 is being unfolded, after the ends of the folded carrier have been pressed towards one another, the panels 136 and 138 are bent downwardly. This has the advantage of pressing the upper panels of the bottom structures downwardly so as to lock them in position.

With this change, the large receptacle 39 can be used to hold popcorn, fried chicken, or other particulate foods such as French fries, etc., directly, without the use of “buckets”. This is highly desirable as a cost-saving feature.

FIG. 9 shows a blank for a carrier substantially like that shown in FIGS. 7 and 8, except that it is of a size to hold only two beverage cups in the receptacles 35 and 37. In other words, the blank shown in FIG. 9 would be somewhat longer for a four-cup carrier.

As before, fold lines are marked with the letter “F”, and areas to be glued are marked with the letter “G”. In addition, some of the cut lines are marked with the letter “C”.

One of the differences between the carrier shown in FIGS. 7-9 and the carrier shown in FIG. 1-6 is that the flaps 42 and 44 which are used to secure the side-walls to the vertical support panels extend from the right end of the panels 30 and 32, instead of from the left end of the vertical support panels.

In addition, it should be understood that one of the flaps 38 and 40 may be omitted, if desired, so that the joint at the rear wall of the carrier is formed by a single flap glued to the vertical side-wall.

It can be seen that the material for the security panels 136 and 138 is taken from the material which forms the third and fourth plies of the handle structure shown in FIG. 1. Thus, the handle structure of the embodiment shown in FIGS. 7-9 is only two-ply instead of four. However, this is not believed to be a substantial disadvantage.

FIG. 9 shows the main reason for the extended height of the walls 26, 28 and 34. They are extended to a height such that the side-wall material extends to the cut line “C” in the center of FIG. 9. This greatly facilitates the automatic formation of the carrier in modern fabrication equipment.

Additional Embodiment

FIGS. 10 and 11 show another embodiment 150 of the invention. The carrier 150 is very similar to the carrier shown in FIGS. 7-9, and the components of the carrier 150 are the same, with certain exceptions. Accordingly, the same reference numerals have been used, where applicable, in FIGS. 10 and 11.

One difference is that the carrier 150 is shorter than the carrier 131 shown in FIG. 7, and the walls 26, 28, and 34 are taller so that the third receptacle 39 is roughly the same height as the vertical support structure 12.

The front portions of the side-walls 28 and 34 are shorter than in FIGS. 7-9 so that the receptacles 35 and 37 for beverages are not as deep as in the embodiment shown in FIGS. 7-9.

In addition, the divider structure is different.

Referring now to both FIGS. 10 and 11, first divider panels 160 and 166 are hinged at the sides along lines 159 and 165, respectively to the vertical support panels 18 and 20. The panel 160 has a side tab 172, and the panel 166 has a side tab 174.

The panel 160 has an extension panel 162 which extends upwardly from and is joined thereto along a fold line 161.

Similarly, a panel 164 extends upwardly from the panel 166 and is joined to it along a fold line 163. The panel 162 has a tab 168 extending upwardly from its upper edge, and the panel 164 has a tab 170 extending upwardly from its upper edge.

When the carrier 150 is opened, after the side edges of the folded carrier are pushed together to pop the carrier open, the panels 160, 166 are bent outwardly until the tabs 172, 174 enter the slots 184, 186. Then the panels 162 and 164 are folded downwardly along lines 161 and 163 until the tabs 168 and 170 enter slots 176 and 178, respectively, in the bottom walls of the receptacles 35 and 37. This provides a second anchor point for the divider structure and closes the opening below the divider panels 160 and 166. This also helps to hold the top panel of the bottom wall in place.

As it is shown in FIG. 11, a slot 180 or 182 is cut into the outer edge of each of the flanges 108 and 106, respectively, at a location to align them with slots 178 and 176 to avoid blocking the entry of the tabs 168 and 170 into the slots 176 and 178.

In accordance with another feature of this embodiment of the invention, a pair of upper panels 188 and 190 are cut out of the material of the side-walls 28 and 34, respectively, and are provided with an attaching structure to attach the two panels together. This step is the final assembly step, and it closes the upper region of the front side-wall of the receptacle 39. Thus, receptacle 39 is tall enough to provide a large receptacle for holding popcorn or other such objects without the need for a “bucket” or any other separate container.

The two receptacles 35 and 37 provide room for two beverage cups, and the receptacle 39 can be filled with popcorn, thus providing a very convenient means for carrying beverages and popcorn.

Referring now to FIGS. 12 and 13, as with the other embodiments of the invention, a tray 210 with a slotted bottom 212 can be fitted down over the top edge of the vertical support structure 12 to provide an auxiliary receptacle in which to place candy, hot dogs, and other solid food items, so that all of the items can be carried in a single carrier using only one hand.

The auxiliary tray 210 includes side-walls 214,216, 218, 220, and corner tabs 222, 224, 226, 228, which are secured to glue tabs foldable along diagonal lines F to make the tray 210 foldable to be flat.

The slot 220 in the tray bottom 212 extends all the way to one side-wall 214 of the tray so that the side-wall 214 fits into the space between the left edge of the vertical support structure 12 and the panels 188, 190 in order to slip the tray 210 onto the vertical support structure. As shown in FIG. 13, the side-walls of the tray 210 are vertical.

The manner in which the two panels 188, 190 are fastened together now will be described.

As shown in FIG. 11, panel 188 has a pair of spade-shaped projections 196, 198, and panel 190 has a pair of wide slots 200, 202, which are rectangular or square in shape. The slots and projections re positioned so that the projections 196, 198 can be forced through the slots, as shown in FIG. 20, to secure the two panels 188, 190 together.

The projections are wider than the slots, and have inwardly-cut lobes which lock the projections in the slots.

Thus, the panels 188, 190 are locked together to complete the fourth side-wall of the tall receptacle 39. The receptacle 39 is tall enough to form a popcorn receptacle which needs no other container on hold a full measure of popcorn for the hungry moviegoer.

Materials

The materials of which the carrier 10 can be made will vary depending upon the intended use of the carrier. Normally, relatively low cost materials such as untreated fiberboard will be sufficient. SUS water-resistant coated board can be used to provide additional resistance to weakening due to spilled liquids. If the container is to be used to hold foods such as popcorn or fried chicken, which are laden with cooking oil or other oily substances, the board materials can be selected to be resistant to absorption of “bleed-through” of such substances.

The above description of the invention is intended to be illustrative and not limiting. Various changes or modifications in the embodiments described may occur to those skilled in the art. These can be made without departing from the spirit or scope of the invention. 

1. A carrier comprising a vertical support panel structure having a hand-hold structure, first, second and third receptacle structures secured to said vertical support panel structure and unfoldable to form first, second and third receptacles, said first and second receptacles being located on opposite sides of said panel structure, said first and second receptacles comprising a pair of compartments having side-walls including a portion of said support panel structure and extending outwardly from said support panel structure in a first direction, said third receptacle extending laterally away from said first and second receptacles in a direction transverse to said first direction, each of said receptacles having a bottom wall, said third receptacle being substantially larger in volume than either of said first and second receptacles and having side-walls substantially taller than said side-walls of said first and second receptacles, a divider wall separating said third receptacle from said first and second receptacles, said divider wall including a first divider panel in each of said first and second receptacles, attached to a vertical edge of said vertical support panel structure along a fold line and being dimensioned to span the distance between and to be attached to one of said side-walls.
 2. A carrier as in claim 1 in which said first divider panel has a lower edge spaced upwardly from said bottom wall of said receptacle, said divider wall including a second divider panel in each of said first and second receptacles, said second divider panel being secured to the upper edge of said first divider panel along a fold line, said second divider panel being foldable downwardly and dimensioned to cover the space between said first panel and said bottom wall.
 3. A carrier as in claim 2 including means for securing said first divider panel to said one side-wall, and said second divider panel to said bottom wall.
 4. A carrier as in claim 1 including an upper divider panel for each of said first and second receptacles, said upper divider panel being formed from a panel forming a side-wall of said receptacle, said upper panel being folded along a vertical line at the location of said divider wall, said upper panels having means for securing them together to form the upper portion of said divider wall.
 5. A carrier comprising a pair of side-wall structures, each having a series of at least four side-wall panels connected together along fold lines, each of said structures including two large side-wall panels which are substantially longer than the others in said series, one of said long side-wall panels in one of said side-wall structures being secured to one of said long side-wall panels in the other of said side-wall structures to form a vertical support panel structure, a portion of each of said one wall of each of said side-wall structures being removed and folded away from said one wall, said portions forming divider walls to separate said two receptacles into one large receptacle and two smaller receptacles, one of said smaller receptacles being located on each side of said vertical support structure, and a plurality of flanges, each extending from the lower edge of one of said side wall panels and connected together to form a bottom wall for each of said receptacles.
 6. A carrier as in claim 5 in which said side-wall structures in the portions forming said large receptacle are of a first height, and in the other portions forming said smaller receptacles is of a substantially smaller height, the upper areas of said other side-wall portions being folded to form upper portions of said divider walls.
 7. A carrier as in claim 5 in which said side-wall structures in the portions forming said large receptacle are of a first height, and in the other portions forming said smaller receptacles is of a substantially smaller height, in which each of said divider walls has a lower edge spaced upwardly from said bottom wall to form an opening, and in which the upper area of each of said removed portions is folded over downwardly onto one of said divider walls and is dimensioned to cover said opening.
 8. A carrier as in claim 5 in which said flanges forming each of said bottom walls are interconnected so as to unfold automatically when said carrier is unfolded.
 9. A carrier as in claim 8 in which flanges at opposite corners of said bottom wall are secured to an adjacent flange along a diagonal fold line.
 10. A carrier as in claim 6 said upper areas bearing locking structures to lock said areas together to form an upper divider wall.
 11. A carrier as in claim 5 in which said side-wall structures in the portions forming said large receptacle are of a first height, and in the other portions forming said smaller receptacles is of a substantially smaller height, the upper areas of said other side-wall portions being folded to form upper portions of said divider walls.
 12. A carrier as in claim 5 in which said vertical support panel structure is closely adjacent at least one side-wall of one of said receptacles, and including an auxiliary tray having side-walls and a bottom wall with an offset slot ending adjacent one of said side-walls, said slot being dimensioned to allow said vertical support panel structure to pass through it. 